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BULKDUST MATERIALS CONTROL HANDLING & EXPLOSION • POWDER PROTECTION HANDLING•• HEALTH QUARRYING & SAFETY • RECYCLING • POWTECH & WASTE 2017 MANAGEMENT PREVIEW

FEBRUARY AUGUST 2017

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Why do we blame robots when the line stops?

HIGHLIGHTS:

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Second silo supports Albis expansion

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Dynamic Air Exhibiting at Powtech

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Protecting against organic dust explosions


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Dynamic Air Ltd. Milton Keynes United Kingdom Phone: +44 (0) 1908 622344 E-mail: sales@dynamicair.co.uk

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Dense Phase Transporter, J-Series

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Issue 121

CONTENTS 4

NEWS

16  COVER STORY 18  POWTECH 2017 PREVIEW BST TEAM Sales Director: James Scrivens Production: Sarah Daviner Accounts Manager: Katie Brehm Office Manager: Susan Daley BULK SOLIDS TODAY is published 6 times a year by Abbey Publishing Ltd ADVERTISING & EDITORIAL Please contact us at: Tel: 01933 316931 Email: editorial@bulksolidstoday.co.uk advertising@bulksolidstoday.co.uk Web: www.bulksolidstoday.co.uk Twitter: www.twitter.com/BulkSolidsToday

21  BULK MATERIALS HANDLING 28

DUST CONTROL & EXPLOSION PROTECTION

31

SPECIAL FEATURE

32  HEALTH & SAFETY 34

BUYERS GUIDE

CIRCULATION To receive a copy free of charge, please send your details to subs@bulksolidstoday.co.uk SUBSCRIPTIONS Subscriptions are available via www.bulksolidstoday.co.uk/subscribe No part of this publication may be reproduced by any means without prior permission from the publishers. The publishers do not accept any responsibility for, or necessarily agree with, any views expressed in articles, letters or supplied advertisements.

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SOME MANUFACTURERS & SUPPLIERS HAVE MADE A CONTRIBUTION TOWARD THE COST OF REPRODUCING SOME PHOTOGRAPHS IN BST.

ISSN: 1365/7119 All contents © Abbey Publishing Ltd 2017

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www.bulksolidstoday.co.uk Bulk Solids Today

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COMPANY NEWS

HOSOKAWA REPRESENTS SMES ON GOVERNMENTS INDUSTRIAL DIGITISATION REVIEW

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osokawa Micron Ltd is among a group of businesses from across the UK participating in a review for Government of ‘Industrial Digitalisation’ and how to unlock the opportunities it presents. The review, chaired by Juergen Maier, CEO of Siemens UK, was announced in the Government’s Industrial Strategy Green Paper published in January 2016. Other participating companies include IBM, GSK, BAE Systems and Rolls Royce. Hosokawa Gen4 was the subject of an SME case study presented to industry leaders at the Artificial Intelligence

workshop held at the Advanced Manufacturing Research Centre’s Factory 2050 in Rotherham. Hosokawa Gen4, offers a smart support service that converts field data from equipment and systems into practical plant operating solutions and a structured approach to smarter supply chains and manufacturing processes. Uniquely combining machine capability and controls expertise, it offers the potential for intelligent manufacturing to gain production improvements. Says Managing Director, Iain Crosley, ‘We are proud to be a part of this industry changing review evaluating

how UK industry can best lead the global race to gain a competitive manufacturing edge from the accelerated adoption of digital technology. Identified by Juergen Maier as a ‘cure for the British economy’ the review is seen as the basis of a strong partnership deal between government and business and as an SME are reassured that we will play a recognised and valuable role in the debate and the future of the UK economic resurgence.’ Tel: +44 (0) 1928 333139 Email: info@hosokawagen4.com www.hosokawagen4.com

TRANSFORMING CUSTOMERS’ BUSINESS - NEW DISTRIBUTOR FOR ALLU

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LLU is proud to announce that FRC Ingeneria as its new distributor throughout Colombia. The company will not only be supplying a comprehensive range of ALLU Transformer attachments, but will also be providing full aftermarket care, spare parts and dedicated customer service. ALLU’s world leading Transformer series needs no introduction; but now customers throughout Colombia will be able to benefit from even greater levels of support through its new distributor, FRC Ingeneria. The formal announcement of the distributorship was made during a recent visit by the company to ALLU’s factory in Finland. The appointment of such a professional and experienced industry distributor reinforces ALLU’s commitment in providing even greater levels of customer focus. It further enhances locally focused customer support, whilst at the same time enabling customers to benefit from dealing with a truly global company. Founded in 2003, Bogota head quartered FRC Ingeneria is an established name through Colombia, with offices and workshops as well as service engineers located throughout the country. Additionally, when the 4

Bulk Solids Today

Ola Ulmala, CEO ALLU, with FRC Ingeneria’s managing director Fernando Bautista and sales manager Nicolay Moreno.

situation requires it, the company will be able to call on round the clock support from ALLU’s regional office. This will further enable customers to benefit from the specialized advice and assistance that has made ALLU the world leading supplier of material processing attachments – the Transformer series. Of the appointment of FRC Ingeneria,

Marjut Lindroos, Group Marketing Manager states: “We are sure that the combination of ALLU equipment and global aftermarket support, together with the local knowledge and industry expertise of FRC Ingeneria, will enable ALLU customers throughout Colombia to benefit from a winning combination.” www.allu.net


COMPANY NEWS

BULKEX – THE MUST-VISIT BULK HANDLING EVENT OF 2017 With a dozen speakers giving presentations on topical and technical topics, plus a supporting exhibition and awards dinner, BULKEX17 is an event not to be missed.

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REXIT, biomass, digitalisation and new technology are just some of the subjects that will be discussed during the twoday conference, organised by the MHEA, on 18 and 19 October. Bulk Handling Today and Tomorrow is living up to its promise with seminars from a dozen key speakers from prominent organisations including the Institute for Government, UKTI, Port of Tyne and Siemens. The high-quality and diverse programme of presentations is proving a draw for professionals from within the bulk handling industry and across vertical sectors such as mining, quarrying, energy, ports and transport. CENTRAL LOCATION BULKEX’s new venue, Eastwood Hall near Nottingham, is a popular choice

too - the delightful Georgian hotel provides a picturesque setting for the occasion. Its Midlands location, close the Nottingham and the M1, is easily accessible from most parts of the UK. Delegates can enjoy a special rate to stay at this relaxing spa hotel with its mix of period and contemporary elegance, bookable with their registration. VALUABLE OUT-OF-OFFICE TIME Many of the industry’s leading companies and key influencers will be attending BULKEX, and taking advantage of the chance to combine information gathering, business insight and networking under one roof with clients, colleagues, end-users and suppliers. Included in the ticket price (£60 for one day, £100 for two days) is the speaker programme and full access

to a supporting exhibition of over 50 stands, plus lunch in the main restaurant and unlimited refreshments. Delegates will also have the opportunity to meet the speakers to find out more about their specialist subjects in addition to the 10-minute question and answer session which follows each presentation. Michael Kaye, President of the Materials Handling Engineers Association, said: “From ports, transport and power, to cement, steel, mining and quarrying, ‘Today and Tomorrow’ will be highlighting key sectors effecting change now and those planning for the decades ahead. “With so much change on the horizon for Britain, BULKEX17 looks set to be the best conference yet with such a broad range of subjects of significant interest to the bulk handling industry and beyond.”

BULKEX SPEAKERS AND TOPICS INCLUDE: • Joe Owen, Senior Researcher, Institute for Government –  BREXIT and trade: Key considerations the government faces and the implications for businesses • John Pethullis, Director, Southdowne Solutions – Ecostore Biomass Storage • Steven Harrison, Operations Director, Port of Tyne and Ian Atkinson, Engineering Director, CS Spencer –  Build of a biomass import facility to cater for Lynemouth Power Station coal to biomass conversion • Gary Chapman, Minerals Account Manager, Siemens – Digitalisation for the bulk handling industry, what it means 6

Bulk Solids Today

Joe Owen

Steven Harrison

in realising real value through asset and data management • Chris Every, Commercial Director, Coomtech – New non-thermal technology for efficient, low cost drying of granular and powdered bulk materials. • Darryn Quayle, Mining Engineer and Specialist, UKTI – Doing business in Latin America: a focus on the benefits and business opportunities in Chile • Matt Drew, Managing Director, Saxlund International –

Gary Chapman

Darryn Quayle

Designing a successful alternative fuel feed system • Dave Wood, Manager Application Specialists, Flexco – Documented reductions in breakage, dust and spillage at transfer points in the coal, grain and wood pellet industries • Declan Barry, Managing Director, Atex Explosion Hazards – How to establish your basis of safety for explosion hazards in bulk materials handling.

For more information and to register visit Bulkex.co.uk


BULKEX N

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Technical Conference • Awards Dinner • Exhibition Nottingham 18-19 October

Bulk Handling Today and Tomorrow

Organised by the Materials Handling Engineers Association

mhea.co.uk/bulkex-17


COMPANY NEWS

KEYLINE PROMOTES ADAM FRANKLIN TO REGIONAL DIRECTOR

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eyline has announced Adam Franklin as its new Regional Director for the South West following the departure of Dean Pinner, who has taken up the role of MD at CCF. Adam, who has worked at Keyline for four years, originally joined the business as Regional Sales Manager for the South East in February 2014. He brings a wealth of experience to the role having been in the industry for over 18 years working for national brands in both operations and sales. Adam is one of Keyline’s ‘succession planning’ success stories, which is an initiative that aims to equip Keyline’s

employees at all levels with the knowledge, skills and training necessary to fulfil their full potential and reach their desired career goals. Adam’s role will involve overseeing the operations and sales for the region, and continuing to build on Keyline’s excellent reputation in the area for being the first choice for civils and drainage. Commenting on his new role, Adam said: “This is an exciting new venture for me and something I have been working towards for the last couple of years. I am surrounded by a great team and I am very much looking forward to continuing to further develop the region and

building on its existing success.” For details about Keyline’s range of products, please visit www.keyline.co.uk

ALL METALS RECOVERY WITH ERIEZ AT RWM 2017

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riez will be showcasing their ECS module for complete ferrous and non-ferrous metals separation on stand 5P10-Q11 at the Recycling and Waste Management show taking place at the NEC, Birmingham from the 12th to 14th of September 2017. Eriez’ extensive range of recycling equipment, which includes Overband Magnets, Eddy Current Separators (ECS), Metal Separators and Magnetic Drums, allows for the consistent recovery of valuable metals helping waste material processors increase their profits. Eriez’ Eddy Current Separator modules have become a key product in the company’s range of recycling equipment over the last few years, providing an economic and efficient solution for all metals recovery. The separation performance that the modules offer has been well received by customers, some recovering the capital equipment cost in a matter of months. The stand-alone unit incorporates a vibratory feeder to control the material feed, a permanent magnetic drum to remove ferrous metals and the high performance RevX-E ST22 Eddy Current Separator, which offers unparalleled separation on non-ferrous metal particles as small as 2mm in size. Visitors are encouraged to bring sample materials to stand 5P10-Q11 to allow Eriez to demonstrate the superior 8

Bulk Solids Today

performance of the metals separation unit. At RWM this year, Eriez will be co-exhibiting with Pellenc ST, leader in optical sorting solutions for waste treatment and the recycling industries. The

collaboration at RWM will give companies processing and recycling metals and waste access to a complete range of products, providing the best solutions for maximising recovery with limited loss. On exhibiting at RWM, Gareth Meese, Sales Director at Eriez Europe says; “Our sales into the recycling industry continue to grow very strongly, which is testament to the exceptional separation efficiency of our equipment

and the high levels of service and support we give to our customers across Europe. At RWM this year, we feel it is important to showcase the full separation solutions we offer and to build on our recent success. There’s a lot of synergy between Eriez and Pellenc ST and the products we offer to the recycling industry and we’re pleased to be collaborating with them at the show.” The team will be on hand at RWM to offer demonstrations and to answer any questions visitors may have regarding metal separation solutions. To make an appointment with the team or to visit the recycling test facility, contact Eriez on +44 (0) 29 2086 8501 or email info@eriezeurope.co.uk


COMPANY NEWS

WAVIN SIMPLIFIES INSPECTION CHAMBER SELECTION WITH NEW ONLINE TOOL

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avin, the UK’s leading manufacturer of plastic piping systems, has launched a new Inspection Chamber Selector to help customers choose the best products for their projects quickly and easily. The online tool requires users to simply answer four questions about a project, including the diameter of outgoing and incoming pipe and the number of properties the installation will serve. From this information, the Inspection Chamber Selector will then generate a report detailing the different solutions available for the given specification. The report also provides corresponding part numbers for each component selected, meaning specifiers and contractors can take the report to a merchant to fulfil the order. When selecting an inspection chamber, there is often more than one

solution available to meet a particular project requirement. With this in mind, Wavin’s Inspection Chamber Selector offers a choice of relevant components which can be used. Martin Lambley, Product Manager for Foul, Utilities & Water Management, commented: “We have an extensive range of inspection chambers available across our portfolio for many different applications. However, this can make product selection a time-consuming task. “We therefore created the selector tool to better guide our customers in choosing the most suitable products for their projects. Since users can only select components that are compatible with one another, the tool also gives customers the added reassurance that the inspection chamber they select will work effectively within the entire foul water system.”

The Inspection Chamber Selector features components and chambers from across the Wavin, OSMA and Hepworth Clay product ranges. Wavin’s inspection chamber range includes shaft diameters from 200mm to 600mm, with both single and multiple inlets and outlets from 110mm to 300mm. To use the Inspection Chamber Selector, visit: www.myportal. wavin.co.uk/tools/chamber, or go to bit.ly/inspection-chambers to find out more about Wavin’s inspection chamber range.

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Bulk Solids Today

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COMPANY NEWS

ETTLINGER AT FAKUMA 2017:

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ttlinger Kunststoffmaschinen GmbH, manufacturer of high performance melt filters and injection moulding machines for high shot weights, will show a brand new generation of melt filters at the upcoming Fakuma 2017. Ettlinger filter systems have already set important efficiency benchmarks on several occasions in the past. The new generation which will be premiered at the Friedrichshafen exhibition will raise the bar even higher in every respect. The first few months of practical experience with pilot customers have confirmed an up to 28% increase in throughput for the same filtration quality and the same ultra-low melt losses. Users profit from more productivity when recycling contaminated waste plastics from industrial or consumer sources. Furthermore, Ettlinger filter systems can in future be very easily integrated into Industry 4.0 environments. Volker Neuber, Managing Director Ettlinger: “Waste streams vary enormously in quality, and the ability to supply high quality recycled polymer at competitive prices is more of a challenge than ever. Our latest filter generation provides the answer: our existing series are already extremely efficient but we’ve now achieved a new landmark.” The new Ettlinger filters work with a rotating, perforated drum – the principle already familiar from the ERF and ECO series: there is a continuous flow of melt

through this drum from the outside to the inside. A scraper continuously removes the contaminants that are held back on the surface and feeds them to an exit screw or discharge shaft. This enables the filter to be used fully automatically and without any disruptions over a period of weeks and months without having to replace the screen. The advantages of this design are the constant melt pressure, ultra-low melt losses – recognized throughout the industry – and good mixing and homogenizing of the melts. Whereas the ERF series is optimised for separating foreign particles from heavily contaminated polyolefins and polystyrenes, the ECO series is ideal for filtering polyolefins, PET and PA as well as recycled material containing up to 1.5% contaminants during the extrusion of films, sheets and other semifinished products. HIGH-VOLUME MACHINES FOR 100 KILO MOLDINGS Although Ettlinger will not be showing its srm series of injection molding machines for shot volumes up to 180,000 cm³ and component weights up to 120 kg live at the Fakuma booth, the latter is nonetheless expected to be a popular port of call for manufacturers of such products. Their defining feature is the structural separation of the melt processing and injection units, which

makes them far more energy efficient than conventional machines. Ettlinger’s injection moulding specialists will be at hand throughout the exhibition week to discuss the specific problems of this niche segment with visitors and explore potential solutions to current issues. Ettlinger Kunststoffmaschinen GmbH was founded in 1983 and is today a global player. The company has its headquarters in Königsbrunn, not far from Augsburg. A sales and service subsidiary opened in Atlanta (Georgia) in 2013. Its core competency is in the development and manufacture of injection moulding machines and high performance melt filters. On the melt filtration side Ettlinger makes systems for continuous filtration of feedstock with varying degrees of contamination. Contaminants like paper, aluminium, wood, silicones or high-melting polymer composites can be removed from all standard polymer materials. Ettlinger injection moulding machines are optimised for the production of polymer mouldings up to 100 kilograms in weight such as plastic pallets, fittings, or manholes. www.ettlinger.com

B&B ATTACHMENTS APPOINTS BUSINESS DEVELOPMENT MANAGER

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&B attachments Ltd, is delighted to announce the appointment of John O’Boyle as its Business Development Manager. John has an impressive background within the attachment industry. He has built up extensive product and application knowledge and gained a vast amount of experience throughout his career. His previous roles include Service Manager and Technical Manager positions within the forklift truck attachment industry. John will now be using his 22 years’ industry knowledge and expertise to build upon B&B’s presence and reputation as the UK’s leading independent supplier 10

Bulk Solids Today

of forklift truck attachments. Based in Lancashire, John is responsible for UK business development activities, which include driving new business across B&B’s Sales, Hire and Service Divisions. He will be responsible for securing targeted sales by developing relationships and industry networks through the penetration of new and existing markets. John will also represent B&B at trade exhibitions, conferences and events to identify potential new customers. Neal Fowler, Sales Director at B&B comments “John O’Boyle is an outstanding appointment for B&B and we are delighted to welcome him as a key member of B&B’s Management

team. John’s appointment is a crucial element of B&B’s growth plans, his role is central to the development of our commercial operations. I am convinced that his personality, broad commercial and technical expertise as well as his network in the industry will make him very successful at B&B. John enthuses about starting his new role “I am eager to use my experience and knowledge to develop and grow customer relations at B&B. I am looking forward to the challenge of driving success across all divisions of the company.” www.bandbattachments.com


COMPANY NEWS

SCOTT GROUP ACQUIRES WHIRLOWDALE

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cott Group has acquired Whirlowdale Trading Co. Ltd (WTC) in a deal which expands access to the range of sustainable pallet solutions available from the Group’s existing pallet businesses; Scott Pallets, HLC and Pallet Logistics. The acquisition of WTC will provide additional operational capacity and capability nationally, particularly in the reconditioned business. Together Scott Pallets and WTC are ideally positioned to offer security of supply and support to customers in all parts of the UK across a diverse range of industry sectors. WTC employs 85 staff and operates its pallet manufacturing and reconditioned business from eight locations in Rotherham (head office and site), Burton, Rainham, Sedgefield, Birtley, Lincoln and Castleford. Alan Gibson, Scott Pallets’ Managing Director, said: “The combined businesses will deliver enhanced security of supply through access to our exceptionally well

established, diverse and controlled reconditioned pallet supply chains. WTC is a well-invested business with a particular strength in reconditioned pallet trading and facilities including strategically located sites, automated pallet production facilities, all adding significant service capability to our current offer”. “Customers will also benefit from our exceptional combined in-house depth of industry knowledge and technical competence. Together this will deliver industry leading, innovative service developments to support our customers, particularly in relation to sustainability and environmental objectives.” Andrew Pearce, previous owner of Whirlowdale, agreed: “I’m delighted to be remaining as a Director of the business and to be able as part of Scott Group to offer customers a more comprehensive choice. Our combined range of pallet products and services,

Left to right: Norman Scott, Group Operations Director at Scott Group; Andrew Pearce, former owner at Whirlowdale

delivered nationally is exceptional.” The deal was supported by HSBC with BTO and Campbell Dallas acting as advisers to Scott Group, and BHP Corporate Finance and hlw Keeble Hawson advising WTC and its shareholders. To find out more, visit www.scottgroupltd.com

Bulk Solids Today

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COMPANY NEWS

MECH-TOOL ENGINEERING SECURES EUROPEAN CERTIFICATION The North East’s largest product manufacturer and global supplier of fire, blast and heat hazard protection solutions has successfully been recognized as an approved manufacturer of CE compliant products.

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eadquartered in Darlington and with offices all over the world including Aberdeen, Houston and Korea – Mech-Tool Engineering Ltd (MTE) – will now be authorized to attach CE markings to its leading range of globally recognised steel and aluminium protection products. Following comprehensive technical reviews at the company’s manufacturing facilities, Lloyd’s Register Quality Assurance (LRQA) – the world’s leading provider of independent assessment services from certification and validation right through to verification and training – has awarded MTE with an EN1090 certification. Under the Construction Products Regulations (CRP), all structural steel and aluminium products must be CE marked when supplied within Europe. The certification – EN1090 – identifies companies that meet this standard which was established to harmonise the safety performance of construction products across the EU. Speaking about the certification, Anthony Jones, Divisional Director at MTE said: “As we continue to provide our safety solutions to companies that operate in challenging and often harsh environments, ensuring that we meet all quality, health, safety and environmental standards to the optimum criteria is of paramount importance at MTE and following procedures is employed meticulously throughout the full business. “Securing this certification will open even more doors for MTE, as it will now allow us to bid for new work across Europe in markets that the business has already well established itself – including nuclear, renewable and power generation – where CE marking applies.” Having carved a reputation for its three business streams – design consultancy, fire and blast solutions and modular solutions – the company announced earlier this year that it has expanded its offering through launching an additional business arm, HVAC Solutions. The new business stream has significantly enhanced the company’s full turnkey modular solutions division, enabling its clients to save time and money with increased capabilities to offer all services under one roof. And the company has already secured its first order to design and build an air handling unit for one of the globe’s leading engineering and technology services business.

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Bulk Solids Today

And the launch of the new business stream came on the back of the company announcing it had secured its largest value contract to date worth £37m. Appointed by Wood Group Mustang and Tengizchevroil (TCO), MTE will deliver a field operations office module and twenty remote instrument enclosure modules for the TengizChevrOil Future Growth and wellhead pressure management project based in Kazakhstan. George Hodgson, Head of Governance Compliance at MTE said: “It is exciting times at MTE as we continue to deliver high profile contracts around the world with compliance at the forefront of everything we do. “We are delighted to have passed the audit for our EN1090 with zero Non Conformance Reports (NCR’s) and the feedback we received from the auditor was incredibly positive on how MTE manage its people and systems. The success of this certification is down to every member of the MTE team, who continually diligently comply with our comprehensive company procedures and systems of work that we have intrinsically adopted.” Established in 1969, MTE offers a complete end to end solution for fire, blast and radiant heat protection from initial design and consultation through to on site manufacture and installation. The company boasts an extensive client portfolio working with the likes of BP, Conoco Philips, Centrica and Talisman. www.mechtool.co.uk


COMPANY NEWS

POWDER SYSTEMS LTD (PSL) PRESENTS PACKING AUTOMATION LTD. WITH E3 BUSINESS AWARD

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n 13th July, Amanda Gowans, Managing Director of PSL appeared before an audience of over 500 North West business delegates as a judge and key sponsor of the 2017 E3 Business Awards. The event took place at the Macron Stadium in Bolton. PSL both judged and sponsored the Manufacturing Business of the Year award, which attracted nominations from across the North West. The winner was Knutsfordbased Packing Automation Ltd. The other shortlisted nominees were: • SPL International • Riggs Autopack Ltd. • Pendle Engineering Limited Acknowledging the high standard of the entries, Amanda Gowans said: “Judging and sponsoring the Manufacturing Business of the Year award for the second year running was an honour for us as it represents excellence in our field of manufacturing in the North West. The standard of those shortlisted across the award categories was extremely high this year. Congratulations to the winners ‘Packing Automation’ and everyone else that won or was short-listed at this year’s E3 awards” PSL is an international designer and manufacturer of filtration, drying and high containment solutions for the pharmaceutical, biopharmaceutical, chemical and laboratory industries.

HOSOKAWA AGREE SERVICE & SPARES PROVISION FOR IIT LTD EQUIPMENT

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eaders in powder and particle processing, Hosokawa Micron Ltd have announced it has signed an agreement with Hippisley Ltd to acquire the Intellectual Property Rights of International Innovative Technologies Ltd. (IIT). The acquisition assigns Hosokawa Micron Ltd the rights to provide maintenance services and spare parts for the range of comminution/size reduction equipment known as the m-series of mills (M350 and M600), the c-series of classifiers and the s-series of cyclone separators. Owners of m-series, c-series and s-series equipment should contact either Dave Lyon dlyon@hmluk.hosokawa.com or Keith Sanderson ksanderson@hmluk.hosokawa.com at Hosokawa Micron Ltd to discuss options for continued equipment after care and spare parts support. Email: info@hmluk.hosokawa.com www.hosokawa.co.uk Tel: +44 (0) 1928 755100

Based in Liverpool, PSL is a previous winner of E3 awards for Manufacturing Business of the Year (2014) and International Business of the Year (2015). www.powdersystems.com The awards evening attracted delegates from all parts of the region, from Cumbria to Cheshire, Merseyside to Manchester. Visitors also came representing a broad range of industry sectors, so it provided an excellent opportunity to raise Packing Automation’s profile amongst some of the North West’s most successful organisations. The E3 Awards were devised to recognise Enterprise, Education and Employment – the three Es. More information about the Awards, including a full list of winners, can be found at www.e3businessawards.co.uk.

High Efficiency Drying or Cooling of Bulk Solids The Bella dryer/cooler offers thermal efficiencies to 80 percent or better because air flows around material while it is suspended in the weightless zone. The result is a more consistent material.

Dynamic Air Ltd. • +44 (0)1908 622344

www.dynamicair.com Bulk Solids Today

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COMPANY NEWS

TENOVA TAKRAF CONTINUES TO SET NEW BENCHMARKS IN BELT PULLEY FABRICATION

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ith headquarters in Leipzig (Germany), TAKRAF is a leading global solutions provider in the mining, bulk material handling and minerals processing industries. The company is also an important manufacturer of high-end components such as belt pulleys and boasts a strong reputation in this area. A contract covering the supply of an approximately 13 km long belt conveyor system was recently awarded by a globally renowned Chilean mining company to TAKRAF. This belt conveyor system will be installed in a copper mine in northern Chile. The scope of work includes, among others, the design, fabrication and supply of 39 belt pulleys specifically developed for this project. All pulleys are being fabricated at the TAKRAF workshop in Lauchhammer (Germany). TAKRAF’s position as a leading global supplier in the engineering and fabrication of belt pulleys enabled it to meet the stringent requirements of supplying highly-stressed drive and return belt pulleys with a maximum diameter of 2.8 m and single weights of up to 60 t. Many of these pulleys will drive and handle the strongest steelcord belt ever employed globally. The various challenges associated with such a project have been overcome by a dedicated team of highly skilled and experienced engineers and workers. 26 of the 39 pulleys have already left the Lauchhammer works, by means of heavy load road transportation with associated special permits; while the final belt pulleys will commence their journey to Chile at the end of August. This extraordinary belt conveyor system, proudly supplied by TAKRAF with belt pulleys designed and made in Germany, will represent a major pillar of Chilean copper production for many years to come. More Infomation: www.takraf.com Tenova TAKRAF is an integrated solutions provider to the global mining, bulk material handling and minerals industries, offering innovative technological solutions as well as process and commodity knowledge along the industry value chains. With 14

Bulk Solids Today

A contract covering the supply of an approximately 13 km long belt conveyor system was recently awarded by a globally renowned Chilean mining company to TAKRAF. The scope of work includes, among others, the design, fabrication and supply of 39 belt pulleys.

the integration of the well-known DELKOR brand of products into TAKRAF, the offered portfolio for the mineral beneficiation and processing sectors has been considerably enhanced. Further information is

available at www.takraf.com. Tenova is a worldwide supplier of advanced technologies, products, and engineering services for the mining and metals industries. Further information is available at www.tenova.com

26 of the 39 pulleys have already left the Lauchhammer works, by means of heavy load road transportation with associated special permits; while the final belt pulleys will commence their journey to Chile at the end of August.


COMPANY NEWS

SECOND SILO SUPPORTS ALBIS EXPANSION

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arton Fabrications has supplied a second 60 ton plastic granule storage silo to global distributor and compounder of technical thermoplastics, Albis UK Ltd. The silos have been installed as part of Albis’ expansion of its bulk supply of thermoplastic raw materials including polypropylene, nylon and ABS. Albis, who represent leading plastic manufacturers and brands, compounds and distributes thermoplastic materials for injection moulding in quantities from 25Kg bags all the way through to 25 ton tanker loads. On site storage of finished polymer is an essential part of Albis’ service as this ensures rapid turnaround of orders. Commenting on the recent silo installations, Jon Cottrill Project Engineer at Albis said: “Barton Fabrications were selected to supply the silos for our Knutsford site. Being ‘good at what they do’ meant a straightforward trouble free installation process. The silos are used to store virgin and recycled raw materials plus finished products for our growing bulk distribution business.” Commenting on the install Mark Barton, MD and owner of Barton Fabrications said: “Although the installation of the silos was fairly simple, proximity to Manchester Airport meant we had to get approval before we could take cranes on site

to carry out the lifting procedure. We were happy to do this; it is all part of the service we offer to ensure trouble free silo installation.” Barton Fabrications is the UK’s largest supplier of aluminium silos: vessels and blenders are produced which are suitable for a wide range of both virgin and recycled plastic feedstock. For more details on Barton Fabrications’ silo solutions, contact Mark Barton:- Tel: +44 (0) 1275 845901 Email: sales@bartonfabs.co.uk www.bartonfabs.co.uk

Other Valves Fight Friction, We Designed it Out Unlike other valves that seal with friction, Posi-flate’s unique butterfly valve uses an inflatable seat to seal with air pressure. Thus it requires less torque and a smaller actuator, resulting in lower cost. Plus, the seat automatically compensates for wear, providing longer life. Some users have reported over six million cycles and the valves are still going strong. s s s s s s

,ESSFRICTION ,OWTORQUE ,OWMAINTENANCE ,OWERACTUATORCOSTS ,ONGERVALVELIFE -ORERELIABLE Tel: +44 (0) 1908 622366

www.posiflate.com

Bulk Solids Today

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ON THE COVER

WHY DO WE BLAME ROBOTS WHEN THE LINE STOPS?

The assumption is that robotics are simply not up to the job, but a closer look is needed to establish the root cause of any malfunction.

Production and packing lines will stop working for any number of reasons, but the default assumption will often be that a robotic malfunction is to blame. Instead of scapegoating the technology, Paul Wilkinson, Commercial & Information Systems Manager at Pacepacker Services, offers some advice on getting to the root of the problem.

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obots are too often presumed guilty when they are not in any position to demonstrate their innocence. We have seen this with the much-discussed ‘threat’ to jobs, despite evidence that it is in the interest of manufacturers to balance automation with the upskilling of manual workers. Likewise, there’s a widespread assumption that, when lines stop working, the cause is hiding inside the ‘black box’ of automation rather than among the humans who manage it. Any statement to the effect that automation over the next decade and beyond will have no

impact on employment should be taken with a very large pinch of salt. But, in its March 2017 report on robotics, PwC forecast that, although up to 46% of UK manufacturing jobs were ‘at potential high risk of automation by the early 2030s’, in many cases those jobs would evolve rather than disappear altogether. By 2030, it is also highly likely that the majority of robotic and automated production and packing lines will not only tell managers why a stoppage has occurred, but probably correct any problem themselves. For now, though, when the robot stops working, the robot will probably get the blame. Sometimes, when there is an element of complexity or variety in the operation, the assumption will be that the robotics is simply not up to the job. Yet, if we are making robots a scapegoat, that probably means we are avoiding other actions which would take us much closer to the root cause of any malfunction.

Correct storage and maintenance of end effectors, such as foam pads on a gripper, is vital

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Bulk Solids Today


ON THE COVER Here are five reasons why the buck should not stop with automated intelligence.

1. A ROBOT IS ONLY AS GOOD AS ITS PROGRAMMING It is essential that robots and other automated sections of the line are programmed to recognise and handle every stockRobots will only operate effectively keeping unit (SKU), including with the correct programming all variants at the primary and secondary packaging stage. This means investing the same amount of time and effort in understanding the full scope of a project as you would do in selecting and specifying equipment in the first place. In product handling and case loading, problems may occur because an integrator has not fully considered the movement of the robotic arm from pick point to place point, the timings on the line, and so on. Preparations should include talking to all of those involved, from operator level up to directors, to ensure that all current and future expectations are understood in detail and can be met in full. The appropriate programming must be available and, just as importantly, easily and reliably accessible. There are other essential elements within the preparation stage. Experienced line operators will be able to predict many of the challenges arising from the nature of the product being handled, different fill levels, poor-quality sealing, spillages and other variables. All of these issues can affect the smooth running of the line, and need to be uncovered and factored into automation planning.

2. THE WORKFORCE NEEDS TO BE ON-SIDE Your workforce can do much more than advise on potential problems. They may initially be wary about the impact of automation, but as an employer, you can turn them into champions of the same technology. You may have reassigned some or all of your workers to other duties in the factory – perhaps being responsible for longer sections of the line, or being trained up to more skilled or technical roles. This happens for the best operational reasons, but can mean that managers are effectively doing away with a critically important layer of visual monitoring and inspection. All operators, and not just those directly responsible for sections of the line, should remain vigilant for any upstream problems which might interfere with its smooth running. Here, managers can play a key role in encouraging those involved to think through to root causes, rather than being satisfied with short-term troubleshooting. Where operators are responsible for setting up the line for changeovers, they need to be given clear training and instructions to ensure all necessary manual and electronic changes are made. If cross-settings, such as guides set to the wrong width, are not corrected, this can jam the line, triggering a shutdown and potentially resulting in lengthy downtime while the problem is Give consideration too for the ‘human factor’. This is not, strictly speaking, human error. Though thankfully rare, there have been cases of workers disabling robots in order to bring significant numbers of manual operators on to the line, complete packing

requirements more quickly and, as a result, leave work earlier. Instead, experienced operators need to be persuaded that the business still relies on them to support and monitor its automated lines. By doing so, they can hopefully be motivated to perform those roles responsibly alongside the new equipment.

3. EVEN THE BEST TEAMS NEED SOUND ONGOING TECHNICAL SUPPORT However trained-up and keyed-up your workforce may be, it makes a huge difference if you partner with integrators which are able to offer strong, ongoing technical support. This is especially true in the area of automation and robotics. Your robots may have been programmed to answer every production need at the time of installation, but needs change. Your customers come up with new requirements, and your production lines have to respond. High-quality technical support means you will be able to assess – and quickly access – different solutions. Wisely, most companies installing automation would see this level of support as a prerequisite for doing business. Yet, it is surprising how often we come across technology that has been mothballed where it could easily have been reprogrammed to fit into a new or modified role. A good supplier should also help to make in-house reprogramming easier. At Pacepacker, we now offer Pallet+ software, which facilitates programming for both palletising and case loading robots, without the need for either engineer visits or the use of a robot teach pendant.

4. GOOD HOUSEKEEPING IS MORE THAN A MAGAZINE Unless systems offer highly sophisticated self-diagnostics, customers should keep an eye on housekeeping and maintenance needs, too. This may simply be a matter of routinely ensuring the line is clean, that there is no accumulation of product residues or dust. These can block vital sensors or jam a belt, for example, triggering an overload. Likewise, line managers need to be aware of wear and tear on key parts of the line and the impact this can have on smooth, uninterrupted operation. Regular checks during scheduled downtime can help to prevent serious failures during production periods.

5. LOVE YOUR END EFFECTORS If a robot is only as good as its programming, it is similarly only as good as its end effectors. Where a single robot is performing multiple actions and handling a range of pack types and sizes, changeovers may involve substituting one of a number of different end effectors. It is essential that processes and training are designed to ensure that the correct tool is always in place. How different end effectors are stored and maintained is also important. For example, if foam pads on a gripper have been compressed in storage, this may mean that it can no longer handle product effectively. Overall, worker ‘buy-in’ is critical to seamless automated production success. And this ‘buy-in’ must happen at all levels. A robotic malfunction is likely to be just part of the story and in most instances you can’t blame the robot for a production blip. In fact, well-programmed and maintained robots can liberate your workforce from mundane, labour intensive tasks, enabling everyone to use their time more productively and pursue more satisfying and professionally challenging career paths. www.pacepacker.com Bulk Solids Today

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POWTECH 2017 PREVIEW

DYNAMIC AIR EXHIBITING OPERATING PNEUMATIC CONVEYING SYSTEM, BELLA MIXER AND VIBRATORY EQUIPMENT AT POWTECH STAND #3-204

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ynamic Air, a world leader in the design and manufacturing of pneumatic conveying systems and process equipment, will be exhibiting an operating pneumatic conveying system as well as the Bella twin shaft mixer and vibratory equipment, at the upcoming Powtech show in September. Dynamic Air manufactures a complete line of dense phase and dilute phase vacuum and pressure pneumatic conveying systems, process Bella Fluidized Zone Mixer equipment and vibratory equipment for handling a materials wide variety of dry bulk granular materials. Each Dynamic Air from bins, pneumatic conveying system is custom-designed to achieve storage silos Dynamic Air Full Line Concept Dense Phase the optimum performance characteristics at the highest Pneumatic Conveying System and hoppers efficiencies. Dynamic Air has developed 16 different pneumatic at any desired conveying concepts, utilizing both pressure and vacuum, feed rate for a consistent and reliable discharge. Dynamic Air’s for handling a wide variety of dry bulk solids to provide a system capabilities include conveying, mixing, drying, cooling, conveying solution that fits the process perfectly. Dynamic agglomeration, weighing, bulk bag unloading, dust collection, Air pneumatic conveying systems can improve efficiency, storage, rail unloading and turnkey installation. reliability and overall quality of the material conveying process. .A fully operational dense phase pneumatic conveying Dynamic Air Ltd. Milton Keynes, United Kingdom system will be on display along with the Bella XN double Phone: 44 1908 622344 E-mail: sales@dynamicair.co.uk shafted mixer in 304 stainless steel food grade design. www.dynamicair.com The Bella twin shaft paddle mixer by Dynamic Air achieves fast, high-capacity, low shear, precision GYRO EX Bin Activating Feeder and Discharger mixing of either dry bulk solids or liquids with solids. Regardless of particle size, shape or density, materials are mixed with a fast, efficient, and gentle action with typical mixing times of 15 to 30 seconds. A weightless zone created by low-speed counter rotating paddles generates very low friction without shear. This makes it ideal for abrasive products and fragile products that cannot tolerate rough handling. Even flakes or spray-dried bodies remain intact Also on display will be Dynamic Air’s line of vibratory equipment including the Stedi-Flo vibratory pan feeder and the GYRO EX bin activating feeder and discharger which produces a controlled gyratory motion to positively withdraw granular 18

Bulk Solids Today


POWTECH 2017 PREVIEW

NEW LABORATORY MIXER FOR THE FOODSTUFFS AND PHARMACEUTICAL INDUSTRIES – EXPANDED R&D CENTER MTI at Powtech 2017 Hall 1 / 1-254

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t Powtech 2017, MTI Mischtechnik presents an all-new line of laboratory mixers developed for the pharmaceutical and foodstuffs sectors. The design corresponds to these industries’ very exacting hygiene requirements; the systems can nevertheless be flexibly adapted to the special needs of diverse applications. The model shown at stand 1-254 in hall 1 was configured at the request of an industry leader who will use it for recipe development in dairy processing. A further highlight is MTI’s UT 250 vertical universal mixer having a working volume of 205 liters; this unit, too, is built to a very high standard. In addition, MTI presents the latest capacity expansion of its R&D Center that will provide further flexibility gains in developing customer-specific machine configurations and in implementing pilot production runs.

NEW LABORATORY MIXER FOR ELEVATED HYGIENE REQUIREMENTS The MTI laboratory mixer premiered at this year’s Powtech fulfils elevated hygiene requirements, whether in homogenising different recipe ingredients or as a friction mixer for carrying out thermal processes. The energy input is adjustable over a wide range via the machine’s rotational speed and hence, the peripheral velocity of the mixing tool. Moreover, the mixture can be tempered by water via the mixer’s double jacket. Thus, the application range of the new laboratory mixer covers broadly diverse process tasks, including coating, agglomerating and vacuum drying. The food-grade model displayed at Powtech provides a vessel volume of 10 liters at a working volume of 2 to 8 liters. The laboratory mixer’s design allows an easy scale-up to industrial operation for recipes and processes developed to volume production standard. Its outer parts and all surfaces in contact with the mixture are made of stainless steel 1.4541, with the latter industrially ground to a grit 1200 high-quality finish. At a drive capacity of 5.5 kW, the rotational speed of the individually configurable mixing tool can be variably selected between 300 rpm and 3,000 rpm adequate to circumferential speeds between 3.7 m/s and 37 m/s. For additional flexibility in the laboratory the mixer can be moved on casters. As has been standard on MTI products for many years, the new laboratory mixer features a clearly structured touch panel and a Siemens S7 control for manual and automatic operation.

STILL MORE VERSATILITY IN DEVELOPING FOR AND WITH CUSTOMERS For a number of years, MTI – with its excellently equipped in-house R&D Center – has been on record as a particularly efficient partner in the development of tailor-made mixer technology. With its most recent expansion, the company’s laboratory provides more scope, e.g., for trials on a larger production scale, as well as a dedicated area for testing under ATEX conditions plus special rooms for mixing products subject

At Powtech 2017, MTI Mischtechnik premiers its newly developed line of laboratory mixers for the foodstuffs and pharmaceutical industries. The version presented at the trade fair is tailor-made for dairy processing needs on behalf of an industry leader. © MTI Mischtechnik

to a high contamination risk. Since October 2016, MTI’s experienced team has been reinforced by process engineer René Weiffen, who brings additional expertise to the task of resolving R&D challenges for, and with, MTI’s customers. Ulrich Schär, General Manager at MTI, comments: “With the launch of the new laboratory mixer for particularly exacting Determined to leave no mixing problem hygiene requirements unresolved, MTI Mischtechnik continues to and the ongoing expand its R&D Center. expansion of its R&D capabilities, MTI emphasises its role as a leading innovator in the mixing industry. Already, our standard line-up of machines meets the conditions for integration into Industry 4.0 environments. But we place an equally strong focus on individual developments addressing highly specific customer objectives. With our ambition not to leave any mixing problem unresolved, we have gained a strong market position among the world’s leading mixer manufacturers in recent years.” MTI Mischtechnik International GmbH, established in 1975, is an internationally leading manufacturer of mixing and processing equipment for the plastics processing, chemical, food and pharmaceutical industries. With a staff of more than 50 employees working at its headquarters site in Detmold, Germany, the company manufactures mixer systems noted for their outstanding mixing performance as well as energy and cost efficiency. The portfolio includes vertical high-speed mixers, horizontal mixers, heating/cooling mixer combinations, universal mixers, laboratory mixers as well as tailor-made systems. E-mail: mail@konsens.de, www.konsens.de Bulk Solids Today

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POWTECH 2017 PREVIEW

POSI-FLATE EXHIBITING INFLATABLE SEATED BUTTTERFLY VALVE IN OPERATION IN STAND #3-301 AT POWTECH

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osi-flate manufactures a complete line of inflatable seated butterfly valves for handling a wide variety of dry bulk granular solids, liquids and gases. Standard sizes are from 2 inch (5 mm) to 30 inch (750 mm) and fit both ANSI and metric flanges. They are offered in a wide variety of construction materials. Stainless steel, ductile iron and aluminium construction is available as standard equipment. Standard finishes include urethane coating, nylon powder coating, epoxy coating, highly polished stainless steel discs and bodies plus almost any custom paint type and colour. Various finishes are also available from custom coatings to highly polished surfaces. Posi-flate will be exhibiting a heavy duty inflatable seated butterfly valve operating next to a typical resilient seated valve at the upcoming Powtech Show in September to demonstrate how quickly a resilient seated valve can wear in comparison to the air operated Posi-flate valve. The inflatable seat design provides a better seal by utilizing air pressure to expand the seat against the disc, providing more sealing area and an even pressure distribution against the disc every time. The seat automatically compensates for wear when it inflates against the disc, extending valve life considerably. The Posi-flate Series 585/586 inflatable seated butterfly valve is designed for the most the most severe of applications. The heavy duty seat has been designed for higher operating pressures and temperatures. The Posi-flate valve is ideally

suited for very abrasive materials such as sand, feldspar, fly ash and most other dry, granular materials, which reduce valve life. Also on display will be Posi-flate’s line of Tork-Mate extended life pneumatic actuators. The Tork-Mate 890 Series actuators achieve up to 15 million cycles maintenancefree, at low cost. They are ideal for 90° and 180° turn devices such as butterfly valves, ball valves, plug valves and damper valves. They meet the latest NAMUR standards, allowing direct or close coupling of NAMUR designed accessories. Custom options include Viton seals, high temperature trim, special finishes, stainless steel pinions, special mounting configurations and special coupling configurations. Tel: +44-1908-622366 E-mail: sales@posiflate.co.uk www.posiflate.com

FREEMAN TECHNOLOGY TO EXHIBIT PIONEERING NEW IN-LINE REAL TIME TECHNOLOGY FOR PROCESS MONITORING

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reeman Technology, the powder characterisation specialists, will be exhibiting at Powtech on stand #4-547 (26-28 September 2017, Nüremberg, Germany). This year the company will be demonstrating pioneering new technology for in-line, real time process monitoring via an exclusive partnership with Lenterra Inc., manufacturers of optical flow sensor technology. Lenterra’s Drag Force Flow (DFF) and Wall Shear Stress (RealShear™) probes provide continuous, real-time data, via optical fibres, enabling users to assess processes and make decisions, without the need to interrupt operations. Freeman Technology’s solutions also include the FT4 Powder Rheometer®, a unique and comprehensive powder tester, which uses patented dynamic methodology, automated shear cells (in accordance with ASTM D7891) and a series of bulk property tests to quantify powder behaviour in terms of flow and processability. This is complemented by the new Uniaxial Powder Tester, which provides an accurate and repeatable measure of the uniaxial unconfined yield strength (uUYS) of a powder to assess and rank flowability. 20

Bulk Solids Today

The company’s material characterisation solutions aim to optimise process performance, increase productivity and improve quality in a diverse range of sectors. The entire product portfolio will be on display at Powtech in Hall 4 Stand 547, where visitors can also pick up a copy of the recently released application note ‘In-Line PAT for High Shear Wet Granulation by Measuring Drag Force Flow’. Representatives from Freeman Technology, including a new Product Manager for Germany, will be on hand throughout the event to discuss all aspects of material characterisation and the challenges associated with powder handling and processing. For more information on the range of products available go to www.freemantech.co.uk. Freeman Technology and Powder Rheometer are registered trademarks of Freeman Technology Ltd.


BULK MATERIALS HANDLING

NEW DEVELOPMENTS IN DOOSAN ADT RANGE Doosan Bobcat EMEA has announced a wide array of new standard and optional features for the company’s articulated dump truck (ADT) range

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he first of the new standard features is an angle limitation system to prevent the truck body from tipping over when it is being loaded with materials. This new function is incorporated as standard on all ADTs manufactured after 1st January 2017 and is also available if requested by customers as a software update for all ‘-5’ machines produced before that date. In the new angle limitation function, a tip limit point can be set to meet the requirements of the machine owner. This allows the body to tip in accordance with the slope of the ground as set by the system. Based on a study of the customer’s application, Doosan can provide recommended limits for the company’s trucks, but it is up to the owner to decide which limits they want to use. If the slope is over the limit, the angle limitation system ensures the body does not move. The function therefore offers increased safety and efficiency as the operator always knows the machine will be in a stable position. Another new standard feature of the ADT range is the engine auto shut down function. ADTs can spend between 30% and 60% of their time standing with the engine idling while they are waiting to be loaded and in some conditions, the waiting time can exceed 60%, with consequent losses in terms of fuel, warranty and service costs. In order to reduce these costs, Doosan has introduced the auto shut down function which can be switched on and off by the operator on the display. Using the system, the operator can set a time after which the engine will automatically shut down if the computer does not detect any activity in the machine. This function is incorporated in all new Doosan ADTs and is available upon customers’ requests as a software update for machines produced before 1st January 2017. Transmission oil levels are among the most complicated features to monitor but ensuring they are maintained at the correct levels is very important for keeping equipment in good shape and is crucial for extending the lifetime of machines and their proper functioning. All new Doosan ADTs are now equipped with an electronic transmission oil level sensor (instead of a dipstick system) which will make oil level checks a much simpler and more reliable process to carry out. The Geofence system offers a new level of protection by ensuring the machine cannot leave a prescribed area. This is part of the machine software and can be set up using a Doosan ADT diagnostic tool. Using the diagnostics, it is possible to adjust the Geofence boundaries and choose a speed limitation level (from 1 to 50 km/h, it is not possible to choose 0 km/h for safety reasons). The speed limitation is activated 15 seconds after the machine crosses the boundaries of the area preset in

the Geofence system. It is available from the factory on new Doosan Stage IV compliant DA30-5 and DA40-5 ADTs. For easier transportation, Doosan has developed a new roof beacon design with a quick release latch to enable operator to prepare the machine for transport in just a few seconds without the use of any additional tools. To meet strict safety rules demanded on some sites, Doosan customers can now order new Sears high performance heated seats. The new seats can be supplied with a choice of three different kinds of seat belt with a 2, 3 or 4 point design. The rear position and direction lights on Doosan ADTs are now LED lights as standard, whilst the work lights, main lights and even the roof light bar are also available in optional LED versions. As well as improving visibility, the LED systems have longer lifetimes. Safety can also be increased by the additional hand rails for service and maintenance work that can now be installed on both the DA30-5 and DA40-5 ADTs. A new protection system for the rear lights avoids damaging the lights when reversing and is particularly useful in very tough applications. There is also the option of a blue or orange flashing rear light which is activated when in reverse gear and works simultaneously with the reverse lights. This is designed to be an excellent additional warning device, especially when working in the dark or on very noisy work sites where normal reverse signals may be not heard. This feature is a mandatory requirement on some sites and is a very popular feature in the UK. The optional electrical refuelling pump may be useful on some job sites as is the air inlet pre-cleaner, which complements the standard high performance 3-step cyclonic air filter in Doosan ADTs, particularly in very dusty areas where the increased amount of dust can cause shorter air filter lifetimes. As a final option, the availability of a new pre-assembly painting system allows Doosan ADT customers to customise their ADTs and specify particular colours if they wish to match them to their existing fleets. www.doosanequipment.eu Bulk Solids Today

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BULK MATERIALS HANDLING

BRIGGS EQUIPMENT ACQUIRES IRISH LIFT TRUCKS

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s part of the company’s 5 year growth strategy, Briggs Equipment is pleased to announce the acquisition of Irish Lift Trucks (ILT) part of the OHM Group in the Republic of Ireland.

Based in Dublin, ILT is a long established dealer of the Hyster range of materials handling equipment serving the Republic of Ireland. This acquisition represents a very exciting opportunity for both Briggs Equipment and ILT to build on the experience and customer base that ILT possesses. Being part of a larger Hyster dealer will allow ILT to grow and expand its offering more quickly than on a standalone basis, providing customers with a broader solution underpinned by Briggs Equipment’s market-leading service levels. There is clear synergy between our two companies, beyond a strong reputation allied to the Hyster brand, and applying our scale to ILT’s marketplace makes good commercial sense. Applying our proven integrated proposition of short and long term rental equipment, asset financing, contract hire, asset management and engineering services to an already solid base can only mean great things for customers, existing and new. We have demonstrated how successful we can be across a large territory, providing nationwide coverage and engineering support. This announcement opens up a wider potential for commercial and industrial businesses across Ireland to achieve their objectives through improved efficiency, greater productivity and the flexibility to adjust their contract-hire assets in response to the changing needs of their operation.

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Bulk Solids Today

This move also allows us to maintain a presence in the EU at a time when the subject of European economic co-operation is going through a period of transition. The next few months represent an exciting time as we deliver on the great potential of the Irish Lift Trucks operation and expand the Briggs Equipment name and reputation to a wider audience. It will be business as usual with existing customers continuing to deal with their usual points of contact. Peter Jones, Managing Director of Briggs Equipment commented, “We are delighted to be able to make today’s announcement. The market that Irish Lift Trucks serves so well is an ideal new market for the proven and successful Briggs Equipment proposition. The versatility of our offering means we have tremendous scope to build on existing relationships and develop new ones.” Declan McCourt, Chief Executive of OHM Group, said, “This is great news for our customers and marks the beginning of the next exciting phase in the development of Irish Lift Trucks. Briggs’ expertise in bringing added value, beyond the supply of OEM equipment, means our current customers and many new companies can benefit from a single source of supply for their industrial machinery. This move makes perfect sense for both businesses and the marketplace in general. It also allows OHM Group to streamline our operations and dedicate our focus on target areas of expansion in our Car, Truck and Power Solutions Divisions.” www.briggsequipment.co.uk


BULK MATERIALS HANDLING

80 GHZ LEVEL RADAR HELPS RECYCLE APC RESIDUE INTO CONCRETE BLOCKS

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astle Environmental is a leading supplier of specialist waste treatment, recycling and disposal services, handling in excess of 250,000 tonnes of waste each year. They operate three fully permitted sites in the UK and are proud to be ISO 14001 and ISO 9002 accredited. One type of waste processed at their Cardiff site is APCr (Air Pollution Control residue), the fine powder that remains following the cleaning of gases from Energy from Waste facilities. It contains lime which is alkaline, and consequently APCr is classified as hazardous waste. For the past 18 months Castle have used recycled APCr as an aggregate replacement in the production of precast concrete products. Following a detailed end of waste review in full consultation with Natural Resources Wales (NRW), APCr is gainfully employed in the manufacture of a range of concrete blocks. The pre-processed APCr is combined with additional aggregates and cement to produce heavy duty interlocking concrete blocks and 4� dense blocks, which are used in construction, civil engineering projects, barriers and bay walls. (See fig 1) Part of this recycling process involves mixing the APCr powder with recycled water in a 4m high agitated vessel to form a slurry which is then dewatered prior to combining with other aggregates to form the blocks. During this mixing process, the level in the vessel requires careful monitoring and control to ensure the process is carried out under the correct conditions. Inside the vessel there is a very agitated surface, solids can build up on the walls as well as the agitator itself and surface foam can also be produced under certain conditions. (See fig 2) The uneven surface, foam and solids build up - are accommodated by the VEGAPULS 64’s 80 GHz radar technology to deliver accurate and reliable level readings. It employs focusing to avoid unwanted interfering signals combined with high sensitivity to read through condensation, sensor build up and to overcome the foaming surface. As well as handling difficult conditions such as these, they are also capable of measuring very low reflectivity

hydrocarbons, even liquid gases, highly pure solvents, past complicated vessel internals, down long nozzles and even operating through process isolation valves. www.vega.com/uk Tel: +44 1444 870055

Figure 1 Useful construction blocks produced using recycled APCr, rather than sending to landfill

BESPOKE SIEVING SOLUTIONS We offer innovative sieving equipment technologies for all industry sectors

MULTISCREEN

Did you know we also offer a remesh service? Figure 2 Challenging conditions - the mixing process produces a very turbulent surface, splashing, surface foam, build up on the walls and vessel internals

farleygreene.com Bulk Solids Today

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BULK MATERIALS HANDLING

MAKING A CASE FOR URETHANE PARTS: 5 KEY FACTORS TO CONSIDER Urethane’s unique properties and versatility is helping to solve some of the industry’s most challenging component design issues By Del Williams, technical writer based in Torrance, California.

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or engineers, meeting part design challenges can be exceedingly difficult when traditional materials like plastic, steel, and rubber do not possess the required specialized characteristics, lack the versatility to be adapted, cannot be economically produced, or do not readily bond with other materials or system components. As a solution to some of today’s complex design challenges, engineers are turning to high-performance polyurethane elastomers. These tough, elastic materials retain their original shape for a long service life, while offering a number of unique properties and capabilities. Here are five key points that make a strong case for why urethane is providing engineers with the design flexibility they need to produce cost-effective parts that meet ever more demanding design specifications. 1. Urethane provides specialized load bearing properties. Urethane offers superior load bearing characteristics that can help to optimize the part. Its ability to sustain higher stresses, as well as withstand both tension and compression, is one of its outstanding characteristics. While it can change shape under heavy load, it will return to its original shape once the load is removed. “Urethane offers elastomeric characteristics that provide a different type of load bearing, not as rigid as plastic or metal, and capable of managing energy in a more versatile way,” says Fred Boyle, senior process engineer at Argonics, one of the U.S.’s largest producers of wear-resistant and customizable urethane products. In terms of load bearing, urethane covers a class of materials that can absorb and release energy under varying loads or impacts in places where metals are not suitable, adds Boyle. Urethane excels, for instance, in impact loading applications such as for bumpers, shock absorbers, die pads, machinery mounts, vehicle suspension mounting bushings, or anything to do with shock or vibration. “Where rigid mounts in oscillating machinery would be subject to fracture or fatigue failure, urethane can absorb that load and decelerate it without shock loading either the component or the stop,” says Boyle. “It can take the load of impact and spread it over a relatively short duration. In cases of varying load, urethane can either dissipate it or return it to the source of the load for reliable, extended, cyclical loading.” 2. Urethane enables maximum abrasion resistance. The outstanding abrasion resistance of urethane elastomers 24

Bulk Solids Today

has led to many important applications where severe wear is a problem. In mining applications, for instance, it withstands abrasive ore, sand, and gravel moving through a conveyor, which can cut and abrade both the steel materials inside, as well as typical rubber skirtings outside that are designed to prevent dust and spillage at transfer points. “Rubber is not as abrasion resistant as urethane, and fancy steel liners do not provide sufficient resistance either,” says Charles Pratt, Operations Manager at Kinder Australia, an independent supplier and manufacturer of conveyor and bulk material handling equipment. Pratt turned to a proprietary urethane formulation by Argonics called Kryptane, an extremely wear-resistant material for applications where abrasion, sliding, or impact occurs regularly. Examples of its use include chute, bin and hopper liners; pipe, fitting and valve liners; impact-and abrasion-resistant plates; blasting curtains and screens; vibration pads; seals and gaskets; as well as truck bed liners, wheel chocks and crossover pads. “In testing for some mining applications, we found that the urethane skirtings on the outside of a conveyor can last 10-15 times longer than rubber,” says Pratt. “Compared to a steel liner on the inside of a conveyor, a urethane liner can get 5-8 times the life.” According to Argonics engineer Boyle, urethane provides a better life and more cost effective solution for abrasion resistance in most applications.


BULK MATERIALS HANDLING “Urethane can be formulated to resist low angle abrasion with high resilience that allows the material to slide, bounce, and tumble along a surface without transferring too much energy into the abrasion-resistant liner,” says Boyle. “For impact abrasion from high angles, it can be formulated to dissipate the impact energy.” 3. Urethane offers a variety of adaptable properties. Because urethane’s properties are tailorable over wide ranges of hardness, resilience, spring rate and dynamic properties, its versatility offers custom solutions to difficult design challenges. “Urethane, even in relatively small quantity production, can be adapted and tailored to prioritize the physical properties that design engineers need,” says Boyle. According to Boyle, for instance, urethane is often used to provide a high degree of resilience, and can return incoming energy to its source, such as for spring applications. This can be done over a long, slow extension or a very quick impact, or the material can be formulated to dissipate the maximum amount of energy when it is more appropriate to cushion an object rather than bounce it. Hardness is also readily adaptable. While most rubbers have a hardness that is typically found between 30 and 80 on the Shore A scale, and structural plastics begin at 55 on the D scale, some urethanes bridge the rubber-plastic hardness range. One proprietary urethane, for instance, offers a wide range of formulations from a 52 shore A to a 70 Shore D to suit a variety of applications. As such, Kinder Australia’s Pratt looked to a proprietary urethane when a unique combination of attributes was required for mining applications to optimize conveyor skirting so it would not prematurely wear the conveyor belt if rubbed against it. “Argonics was able to formulate a conveyor skirting material that was not only abrasion resistant, but also soft and slippery to minimize any potential conveyor belt wear,” says Pratt. “The urethane is very customizable. For applications such as coal mining, you can also make it resistant to fire and temperature as well as anti-static.” 4. Urethane parts can be produced with a low cost, low pressure mold. Urethanes can be poured as a liquid mixture into less expensive, low pressure moulds so complex mold cavities can be filled without highpressure moulds and presses. This provides a multitude of advantages, not the least of which are lower tooling and production costs than both rubber and plastic moulding, and lower material cost than metals and ceramics. Because of short lead times and more economical tooling costs, urethane is often the choice for one-off parts and prototypes, or high volume, repeat production runs. “To produce a good part in the rubber part-making process, you have to apply significant pressure to force the material into all the nooks, crannies and corners,” says Boyle. “This requires rather costly hydraulic presses.”

“Urethane, however, is castable at atmospheric pressure so you can use relatively inexpensive moulds to create prototypes, design iterations, and even production runs more quickly and inexpensively,” adds Boyle. 5. Urethane can bond with an array of substrates. Urethane is versatile in how it bonds with a wide range of substrates such as steel, aluminium, fibreglass and plastic. “Since urethane is cast as a liquid, it can be bonded to a wide variety of shapes and moulded into a wide variety of shapes,” says Boyle. “Urethane can even be bonded to substrates so the bond will be stronger than the urethane. This is an advantage when bonding dissimilar materials, when strength and adhesion are required.” Other conventional materials lack this range of bonding capability. For instance, steel can bond to steel but cannot be reasonably bonded to aluminium; and aluminium can be welded to aluminium, but not attached to plastic in this way. When engineers require unique high-performance properties in the construction of component parts, they can often improve their design by utilizing urethane, and by partnering with an expert provider who can tailor the parts to their exact design requirements. For more information contact Argonics, Inc., 520 9th St., Gwinn, MI 49841; visit www.argonics.com; call 800-991-2746; Email information@argonics.com. Bulk Solids Today

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BULK MATERIALS HANDLING

MAKING THE BEST OF LIMITED SPACE

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culptor Jeff Smith recently advertised the world’s smallest house on holiday lettings site Airbnb for £39 a night. The wheeled trailer only fits one person and can fit inside a regular van. While this limited space may not be for claustrophobes, it does offer porthole windows, a sink and a stove top, showing that even the most restricted spaces can have potential. Here, Hugh Freer, sales director of electric tug specialist MasterMover, looks at how factories can make the best use of limited space. Many factories struggle with limited space, which affects their potential maximum output. Less space means less room to produce components on production lines and less room to manoeuvre the finished components. Fork lifts, for example, require aisles that are three metres wide. This means that the number of production lines in factories is limited by the space needed to move components between them. To maximise profit and productivity, companies should maximise the space available to them in their factory. Rather than wasting large areas in the factory with poor design, companies should carefully consider the layout of their production lines to ensure a smooth passageway for components as they move around the factory. Poor layouts can lead to excess waste. For example, the process of machining metal in the metalworking industry produces a large amount of waste, known as swarf, which is collected in large bins. The waste can weigh up to one tonne so, to remove the bins, the aisles between the production lines need to be extremely wide to negotiate a fork lift truck. These wide aisles reduce the amount of machining production lines that can be setup in a factory. The metal components themselves are often high value, meaning that companies must allow for careful movement around the factory. By using electric tugs, companies can half the space that they need to move materials around the factory. The pedestrian operated tugs can safely move objects up to 30,000kg around the factory, without the necessary space required for forklift trucks. The only space required is the space the component being moved takes up, as the electric tugs themselves are very small. Limited space in factories also presents concerns about

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the manoeuvrability of objects and the potential for accidents. Fork lift trucks pose the risk of crush injuries and foot injuries as visibility can be limited and excess speed can make it hard for a truck to stop. It is often difficult to manoeuvre large objects around sharp turns in factories with limited space. MasterMover’s electric tugs can pivot a load up to 180 degrees, making it easier to move even heavy objects in tight spaces. This increases the range of manoeuvrability and increases the space that can be used in a factory, while reducing the potential of damage to any high value objects. Any handling equipment used in such a tight environment must have safety guards in place to prevent any accidents. Factories should have clear divisions in place between the pedestrian areas and areas where vehicles are used. MasterMover’s electric tugs also have additional safety guards in place to protect employees from the loads being moved. As well as an effective braking system, an anti-crush button on the top of the tug activates when it presses into any object. This protects the tug’s operator from being crushed between the load and another object, unlike forklifts, which rely on the driver seeing the hazard ahead. Safety features like these are effective in busy, small factories where there are commonly many people and objects hurrying around. Having a small factory doesn’t have to be a disadvantage to production if the space is effectively used. Just like Smith’s popular holiday home, the space must be designed and optimised, with the employees using the right equipment to get the best of the space available and to maintain safety for all of its employees. www.mastermover.com


BULK MATERIALS HANDLING

IBC DISCHARGER FOR LOW HEADROOM AREAS

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new BULK-OUT® low profile discharger positions Intermediate Bulk Containers (IBCs) weighing up to 1450 kg in the frame using an electric hoist and trolley, discharges bulk solid materials into a surge hopper and conveys the material to a downstream process dust-free. Lifting arms fitted with four eye hooks connect to the mobile IBC frame, which is equipped with four inverted cradle cups that mate with corresponding posts on the discharger frame for precise positioning of the IBC outlet. When lowered into position, the tapered outlet of the IBC’s butterfly discharge valve mates with a gasketed receiving ring on the lid of a surge hopper, allowing opening of the valve and discharging of material with no dusting. The surge hopper is available with an integral flexible screw conveyor, tubular cable conveyor or pneumatic conveying system also produced by the company. The purpose-built stainless steel IBC hopper frame measures 914 mm square by 965 mm high and includes two swivel and two rigid castors with brakes. Quick-release clamps secure the hinged hopper lid during transport and discharge of material. A port on the lid of the surge hopper is vented to a BAG-VAC™ dust collector that puts the sealed system under negative pressure, preventing displaced air and dust from entering the plant atmosphere. All material contact surfaces of the system are of stainless steel with the exception of the flexible screw conveyor’s polymer outer tube. The company also manufactures bulk bag dischargers, pneumatic conveyors, flexible screw conveyors, tubular cable conveyors, bulk bag conditioners, bulk bag fillers, bag dump stations, drum/box/container tippers, weigh batching and blending systems, and engineered plant-wide bulk handling systems with automated controls. For information contact Flexicon Europe Ltd, +44 (0)1227 374710, sales@flexicon.co.uk, www.flexicon.co.uk

Tuf-Lok ring grip pipe and tube couplings are rugged, heavy duty, self-aligning and self-grounded couplings with a high end pull. They can be used for almost any application where pipe or tube ends need to be connected. The Tuf-Lok self-aligning couplings install quickly and easily with little effort. Features • Self-aligning • Self-grounding • High pressure rated • Full vacuum rated • Stainless or mild steel • Usable on thin or thick wall pipe or tube • Low cost • Reusable • Absorbs vibration • Externally leakproof

Tuf-Lok (UK) Tel: +44 (0) 1706 822512 Email: sales@tuflok.co.uk • www.tuflok.com

Bulk Solids Today

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DUST CONTROL & EXPLOSION PROTECTION

THE RED-HOT RISKS OF GOING GREEN - PROTECTING AGAINST ORGANIC DUST EXPLOSIONS Mark Shannon from BS&B Safety Systems discusses the risks and management of dust explosions in the organics recycling industry. IF IT’S ORGANIC, IT’S COMBUSTIBLE Any industry which handles fine organic dusts is at risk of these materials burning and exploding. Every year, processing facilities are severely damaged or destroyed by dust fires that usually start in dust extraction and waste conveying equipment. Just a few embers entering a dust collector, bin or silo is enough to trigger a dust explosion which would typically lead to fire. By 2020, a European Union directive1 aims to ensure that 20 per cent of the energy consumption of each EU country comes from renewable sources and this includes biomass which requires converting biodegradable matter such as wood, straw and agriculture waste into heat or electricity. With this emphasis on green energy the demand for pellet fuels, made from compressed biomass, has increased rapidly, with wood pellets being the most common type. This increased demand brings an elevated danger of organic dust explosion risk, as wood based recyclables like sawdust or other wastes from sawmilling or wood product manufacture are being processed, stored or handled in bulk. Dust explosions are already a well1 Directive 2009/28/EC 28

Bulk Solids Today

known hazard in wood industries of all kinds. Even with the best-designed and operated production processes, very fine organic dusts from these operations are at risk of causing these materials to burn and explode.

TONER DUST - THE NEW RISK ON THE BLOCK One of the newer recycling risks requiring explosion protection management occurs in the print cartridge recycling industry. Toner comprises carbon, iron and other organic materials. Their combined dust particle sizes are mostly less than 10 μm. This is not unlike other organic dusts which cause explosions in paper, biofuel and other recycling plants, or industries that produce wood based by-products like shredding or pelleting. Dust explosions sometimes occur during the recycling of toner cartridges. As toner powder has become much finer for better copy and print performance, the danger of dust explosions has also increased. In 2008, real awareness grew of toner dust explosion risks after two significant occurrences at toner recycling facilities in Japan. In one incident, the initial explosion ignited in a toner cartridge pulveriser. Dust residue in the cartridges ignited


DUST CONTROL & EXPLOSION PROTECTION during the crushing process, causing a rise in heat pressure in the pulveriser, resulting in an explosion. The primary explosion further propagated when expelled toner dust reacted with oxygen in the air. Subsequent studies of toner particle hazards in relation to dust explosions showed that toner dust particles are possibly more dangerous compared with other organic equivalents. Because organic dusts have different explosive properties, these are often handled and stored in different ways and locations. The protective measures in each location should be tailored to meet the associated risk. However, before application of any solutions, we always recommend that clients test their dust. It may sound strange, however, dusts differ and have varying characteristics depending on the base organic material they come from. Laboratory testing of the dust generated in your factory will inform the type of protection needed to mitigate explosion risk.

ALL ABOUT DUST Dust testing is designed to identify two key performance characteristics of dust, which in turn influence explosion protection equipment design and their application. • The first measures maximum pressure of a dust explosion (Pmax in bar) • The second identifies the speed of the rise in explosive pressure (Kst in m/sec) Different types of dust have different particle sizes, properties, ignition temperatures, and ignition sources, from each other. Dusts are given explosion severity classifications; St1 to St3. ‘Not specified’, means the material is non-explosive and St3 is the most explosive type of material. Testing under laboratory conditions will tell you what St class your dust is, based on its Kst value. It also discloses the dust’s performance when subjected to certain processes; for example, is it being milled, ground, poured or dried? While being subjected to these processes, what is its Minimum Ignition Temperature (MIT)? In other words, what temperature will the dust withstand before it becomes an ignition risk?

EXPLOSION PREVENTION METHODS Having tested the type of dust being generated, there are a range of protective measures one can apply. Whether it’s investment in protection equipment, to improvements in housekeeping thus eliminating the build-up of deposits of combustible dust which may accumulate on beams in the facility. Spark detection devices: sense hot particles, sparks and flames that could become the ignition source for a fire or explosion. They can include automated shut-down systems to interrupt the feed of combustible material along the process equipment. All processes may be monitored by an operative via a control panel to assess any further risks. Spark detection is particularly useful to manage fire and explosion risks in process equipment, such as dust collectors, bins and silos. Chemical suppression systems: designed to detect the pressure wave at the very start of an explosion and deliver dry, inert chemical extinguishing agents into a developing internal deflagration. These suppression and isolation systems can be

activated either by pressure, optical or vent sensors. Any combustion travelling through interconnected equipment is quickly and efficiently extinguished, preventing any spreading explosion damage. Flame free vents: an effective and preferred passive method to relieve explosive pressure in a process or storage vessel containing combustible materials. It is not always practical or safe to vent the pressure and flame to a safe area, therefore these vents intercept, quench and retain all burning materials, preventing them from expelling into the atmosphere. They are particularly useful for dust collectors, bins and bucket elevators. Isolation: designed to prevent any kind of deflagration or explosion from spreading to other parts of process equipment. There are two methods of isolation used: • The Passive method does not require detectors, or control and indicating equipment. It may be achieved by using arrestor mesh, rotary valves, lock valves, rotary screws, flap valves or diversion valves. • The Active method may be triggered by detectors and utilise components such as pinch valves, chemical isolation or fast acting valves. Even though chemical suppression is used to reduce the initial building pressure in an enclosure, some hot gasses will attempt to exit to areas of lower pressure. This causes a flow through the inlets and outlets of the enclosure, hence the need for isolation. There is no substitute for carrying out risk assessments, conducting a factory survey and dust testing to achieve optimal dust explosion protection. At BS&B we would always recommend this course of action to our clients, and remind them of the importance of getting an explosion protection consultant on board to help. It would be futile to install protective equipment if it’s not the equipment you need. It’s important to remember, even though you may be processing seemingly innocuous substances, they have the potential to become lethal in the right conditions. Don’t guess, or hope for the best but be diligent and understand the nature of the risk at hand because lives and livelihoods depend on it. It’s better to be safe than sorry. For more information about how to protect your business against the risk of dust explosion, contact BS&B Safety Systems: Tel: 0161 955 4202 or email sales@bsb-systems.co.uk or visit www.bsbipd.com.

Bulk Solids Today

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DUST CONTROL & EXPLOSION PROTECTION

VAC-U-MAX INTRODUCES NEW AIR-VAC FOR FINE POWDERS & COMBUSTIBLE DUSTS

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AC-U-MAX proudly introduces the newest addition to its Industrial Vacuum Cleaning product range for Combustible Dusts, the new MDL15. The MDL15 Combustible Dust Air-Vac features the exclusive VAC-U-MAX Venturi power unit – which offers the lowest compressed-air consumption on the market today. System features a 15-gallon collection drum, and with no expensive electrical components or moving parts, the MDL15 is ideal for high volume recovery of fine powders and combustible dusts – making it a truly “intrinsically safe system”. For more information on the new MDL15 and to preview a video demonstration, visit www.vac-u-max.com/MDL15. The MDL15 features manual blow-back filter cleaning with static-conductive PTFE pre-filter and secondary cartridge filter, and static-conductive casters. Dust, debris, and fine powders are collected in “off-the-shelf” static-conductive polybags, eliminating “the mushroom cloud” that comes with

drum dumping. Standard construction includes anti-sparking stainless steel in 304SS or 316SS bead-blast finish, and is suitable for food environments. The MDL15 is equipped with a static-conductive compressed-air hose, ATEX-certified vacuum hose, and complete cleaning tool kit assembly for floors, walls, machinery and overhead cleaning. The Single-Venturi Power Unit offers maximum suction power at 16” Hg (208” H20), with maximum Air Flow of 100 SCFM, requiring 35 SCFM @ 60 PSI. Suction connection is 1.5” in diameter, with compressed-air connection at ½” NPT (Female). Noise levels are below 79 DBA @ 8” Hg. Bonding and grounding requirements meet NFPA 77-2007 “Recommended Practice on Static Electricity”. Typical industrial vacuum cleaning applications for the MDL15 include high volume clean-up of powders and combustible dusts from floors, walls, machinery and overhead surfaces typically found in the food, pharmaceutical, chemical and general manufacturing industries. The MDL15 is suitable for Class II, Division 2 environments. For more information and to preview video demonstration, please visit www.vac-u-max.com/MDL15. 30

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SPECIAL FEATURE

VORTEX TPV SAVES TIME DISTRIBUTING ROCK BALLAST Kevin R Peterson – Vortex Business Development Director of Titan Products

P

lacing a layer of rock ballast over the membrane of a rooftop holds the components in place, allows for future building movement, protects the membrane from potentially destructive UV sun rays and weather, and greatly extends the life of the roof. The components of a ballasted roof (insulation, thermal barrier, and waterproof membrane) are not adhered to the roof deck to reduce overall costs and installation time. Vac-It-All is a contracting company that specializes in the preparation of roof surfaces. The company has completed a wide range of projects for multi-level and industrial buildings across both Europe and North America, moving thousands of tons of rock in the process. Whether reroofing or installing ballasted single‐ply or inverted roof membrane systems, Vac‐It‐ All’s method for moving material can greatly reduce the cost of removing or placing rock ballast on the roofing surface.

EFFICIENTLY TRANSPORTING MATERIAL Moving large quantities of heavy rock from trucks to rooftops can be a difficult and time-consuming job. Vac-ItAll uses rock ranging from 20 to 40mm. For many years, the company used a belt conveyor to convey the rock to the roof and then distributed the rock on the roof using wheelbarrows. To speed up the process, Vac-It-All owner Dave Settlemoir designed a pressure pneumatic conveying system that is capable of conveying decking material to roofs up to 10 stories high or 305m horizontally from the initial load point. The system is mounted on a trailer and uses a 255mm conveying line to move material from a hopper to the rooftop, where an operator can direct the material where needed. “When working commercial projects, customers want the roof installed quickly to avoid potential weather issues,” Settlemoir says, “and they want contractor equipment out of the way of their daily business interactions.” Two 255mm Vortex TPV slide-gate valves are key to Settlemoir’s system. Vortex slide-gate valves have a center opening that is the same diameter as the material handling line and a blade (or gate) that, when actuated, slides across the opening to block material flow. The TPV gate valves are designed to handle abrasive dry material, such as minerals, frac sand, and fly ash. The valves’ blades and seats are made of 440 C stainless steel and can be changed-out in the event of wear, increasing the life of the valves. In Vac-It-All’s system, the gate valves are stacked vertically, separated by a chamber. The two valves work together to feed the material into a conveying system without allowing any air pressure to escape. Both gates are initially closed, and the top gate opens for 2 seconds using hydraulics to allow material to fall into the chamber

Workers can now move rock across a rooftop using the conveying line instead of moving it around with wheelbarrows.

from a hopper above. Then the top gate closes and the bottom gate opens for 2 seconds to allow the material to enter the conveying line below. The bottom gate closes and the process repeats as needed. The valves effectively contain the conveying line pressure within the system, and frequent batching allows for a continuous flow of material at the conveying line’s discharge.

QUICKLY MOVING MATERIAL During one particular job, the system allowed Vac‐It‐All to move and distribute 26 tonnes of rock in just over 3 hours. “It normally would have been an all-day process to move this much rock,” Settlemoir says. “Employing equipment that will facilitate project completion is key to our success. The supplier provided reliable component parts for the specialized equipment we develop to help improve our customer services.” For more technical information about Vortex’s TPV Gate or to watch a demo video, see http://www.vortexglobal. com/tpv-high-temperature-slide-gate/ Vortex Global Ltd: Tel: +44 (0) 1325 728 577 http://vortexglobal.com/ Vac-It-All loads the system’s hopper with rock to convey pneumatically through the TPV valves.

Bulk Solids Today

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HEALTH & SAFETY

YOUNG PEOPLE IN THE WORKPLACE ARE NOT TAKING HEALTH AND SAFETY SERIOUSLY ENOUGH More than a quarter of young people are failing to follow the health and safety procedures put in place by their employer and are putting themselves in danger, according to new research.

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he survey of 2,000 employees, working for businesses that have over five employees, found that 27% of workers aged between 18 and 34 have put themselves at risk by not following their companies’ safety procedures. This is despite them being more likely than their older colleagues to read the health and safety guidance they were provided with. It found that half (56%) of people aged between 18 and 34 have read their operations manual, compared to only 30% of 45 to 64 year olds. Even though fewer older people have read their company’s health and safety information, just 8% have put themselves in danger by not following the procedures correctly. The research, which was conducted by award-winning data capture app provider, WorkMobile, also revealed that many younger workers wouldn’t know how to deal with a hazardous situation, despite saying that they have read their handbook. A third (33%) of 18 to 34 year olds admitted they would have no idea what to do if a hazardous situation occurred. But one in 10 (11%) said that while they would not know how to handle an incident at work correctly, they would know where to find the right information to do so. Compared to younger workers, two thirds (67%) of 45 to 64 year olds would know what to do if a potentially dangerous situation at work occurred. The survey forms part of the ‘Work Safe’ report, which looks at the current state of health and safety in the UK and where improvements need to be made to protect workers. Colin Yates, chief support officer at WorkMobile, said: “Ultimately, it’s the responsibility of employers to ensure they are supplying staff with the necessary information and guidance to allow them to work in an appropriate manner. But while most businesses are meeting this legal requirement, it’s extremely 32

Bulk Solids Today

concerning to see is that many young people are failing to take health and safety seriously and are putting themselves in danger by not following the correct procedures. “For business owners, it can be difficult to know whether employees have actually read their handbooks and are up to speed with on the company’s health and safety products. “To make sure young people are following the correct procedures, companies should consider introducing frequent meetings or updates to discuss health and safety in the workplace, so it remains front of mind for employees and they are aware of what to do if a hazardous situation was to occur. It’s important that both employers and employees take health and safety seriously to ensure that everyone is able to work in a safe environment.” http://www.workmobileforms.com/ research-and-whitepapers/


HEALTH & SAFETY

PHARMACEUTICAL MANUFACTURING SOLUTIONS

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he desire to live longer and healthier is a pillar of modern life. Hence the demand for healthcare data, advanced therapies and ever quicker reacting cures in the pharmaceutical industry is so high. With the advances in knowledge comes the advances in manufacturing, with pharmaceutical companies manufacturing six times the average company in the UK. The scale of demand and the free market forces the manufacturing process to become smarter. One way to increase efficiencies is to improve the safety and maintenance of plants. Coltraco Ultrasonics are proud to be assisting British companies in the production of life changing medicine. A British pharmaceutical company – one of the largest in the world - approached Coltraco for an innovative solution to aid their manufacturing process. Coltraco received a request from one of their manufacturing plants in Ireland, which produces active ingredients that are used in drugs to treat cancer, Parkinsons and Depression. At this plant, a mix of ammonia and water is delivered to the site in Intermediate Bulk Containers (IBCs): reusable storage tanks which commonly carry circa 1,040 litres. This ammonia is required at the pharmaceutical plant to breakdown manufacturing by-products before they are then safely incinerated. Previously, the company had been monitoring the ammonia contents through a physical dip stick measurement on the tank, because of a lack of confidence in the internal IBC monitoring systems. However, the fumes given off by ammonia are irritating and corrosive, and can cause burning to the nose, throat and respiratory tract which poses a severe health risk for the engineers. Opening the top valve for the physical dip stick measurement also creates risk of contamination to the ammonia. For this reason, the pharmaceutical company asked Coltraco to deliver a new way to non-invasively monitor the contents within the IBCs. A Coltraco Engineer visited the site to conduct technology suitability trials. A survey of several of the IBCs was conducted, and it was noted that some of the containers were partially full or fully empty. From this, the Engineer determined the general range for a full and empty state across 7 of the IBCs (table below). Trials conducted indicated that Coltraco can provide a solution for this application.

Ultrasonics was the solution chosen by Coltraco, who are experts in this technology stream, for a non-invasive, robust, easy to use avoiding the risk of harm to the site engineers. Coltraco’s equipment is designed to improve safety and best practice, ensuring the equipment used by crew/technicians/engineers to conduct such inspections is accurate and calibrated is a necessary one. For this reason, Coltraco calibrated their Intrinsically Safe Platform to application specific purposes. This was set to – 0 = LIQUID 100 + = Air. The Intrinsically Safe Platform was designed to operate in specific environment where the presence of potentially dangerous gases can be experienced. The solution offered unparalleled accuracy and clarity of indication: the Portalevel® Intrinsically Safe. It provides fast operation and is Zone 1 ATEX Certified and UL Approved. The unit requires no input from the on-site engineer apart from the simple application of the sensor to the vessel wall. This protects the operator from the health and safety problems that were presented through manual monitoring, as well as increasing efficiency. The delivery of a solution to the pharmaceutical company allows the operators of the plant to safely, quickly and accurately monitor the contents within the ammonia vessels. These vessels are integral to the operation of the plant. This unit is also cost efficient, reducing the amount of partially empty ammonia cylinders returned before emptying, increasing efficiency, and saving the organisation money over time. Coltraco strive to provide innovative and personalised solutions to the demands that their customers have, so that their customers can be assured of business success and efficiency. www.coltraco.co.uk https://www.youtube.com/watch?v=zHx3OlH-x3s

Bulk Solids Today

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BUYERS GUIDE Aero Mechanical Conveyors

Conveyors & Elevators

Mixers & Blenders

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Suppliers of the Original EnteconŽ Aero Mechanical Conveyors Other Products: • Sack Openers • FIBC Fill / Discharge Tip or Automatic • Pneumatic Conveyors

Sales office for UK & ROI: SGH Equipment - EnteconÂŽ Agent

Tel / Fax: 01270 651611

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Bulk Storage & Handling

MANUFACTURERS OF SILOS, TANKS AND CONVEYING SYSTEMS Redbrook, Barnsley S75 1HR Tel: 01226 730037 Fax: 01226 730066 Email: info@eb-equipment.com Web: www.eb-equipment.com

Bulk handling with complete confidence Designers and UK manufacturers of: • Bucket elevators • Chain & flight conveyors • Screw conveyors & bin dischargers • Belt conveyors

Dynamic Air Ltd. Milton Keynes, England

+44 (0) 1908 622344 www.dynamicair.com

www.perryengineering.com Tel: 01404 891400 Fax: 01404 891402

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Remote Silo Monitoring


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Dynamic Air

Screw Feeders, Mixers & IBC Systems

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Vacuum Cleaning

AJAX

Farleygreene 23 Hosokawa Micron

9

NORD 36

Screw Feeders, Mixers & IBC Systems

Posi-flate 15

Ajax Equipment Ltd Tel: 01204 386723 Fax: 01204 363706

Primasonics 11

www.ajax.co.uk email: solids@ajax.co.uk

Sieves & Sifters

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Valves 22/10/2013 14:56:57

Tuf-lok 27 Vortex Valves

5

Posi-flate Milton Keynes England +44 (0) 1908 622366

www.posiflate.com

Intermodal dry bulk logistics for polymers, chemicals & minerals Cost effective Environmental savings Reduced C02 emissions

www.InterBulkGroup.com

InterBulk GROUP

Bulk Solids Today

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NORD DRIVESYSTEMS Intelligent Drivesystems, Worldwide Services

Maxx MaxxDrive Drive The MaxxDrive TM range of Industrial Gears are designed to our tried and tested Unicase principle of a one piece housing, into which all the bearings are integrated providing the highest levels of precision, rigidity and strength. This produces a compact, lighter unit that can be mounted in any position and with the use of larger roller bearings guarantee’s a long operating life. There are 9 sizes in the range with ratings of 25,000...250,000Nm, covering motor powers 2.2...2,200kW and with gearbox ratio’s of 5.54...1,600 : 1. Shown below on a base frame with a fluid coupling between motor and gearbox for soft start functionality. The product is fully flexible and can be adapted to suit all applications.

NORD Gear Limited

11 Barton Lane, Abingdon, OX14 3NB Tel. No.:+44 (0) 1235 534404 Email: GB-Sales@nord.com Web: www.nord.com

Member of the Global NORD DRIVESYSTEMS Group

BST August 2017